OLED Through-Hole ETL Structure for Uniform Pixel Thickness
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Solution Overview
Problem
The manufacturing processes of OLED devices face issues with multiple metal masks and low material utilization in vacuum evaporation, and the shape of the pixel defining layer leads to uneven film thickness and current leakage due to precision challenges in inkjet printing.
Innovation Solution
The OLED device incorporates an insulating layer with through holes to precisely define the pixel region, where the electron transport and injection layers are attached to the light-emitting layer, ensuring uniform thickness and preventing current leakage, combining inkjet printing and vacuum evaporation for improved precision and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum evaporation technology is used to manufacture OLED film layers, then manufacturing efficiency is improved, but material utilization rate decreases and multiple metal masks are required
Solution Approach 1:
The patent divides the OLED device into distinct functional regions using a pixel defining layer with through-holes, separating the light-emitting area from the non-light-emitting area. This segmentation allows selective deposition of materials only where needed, improving material utilization while maintaining manufacturing efficiency through vacuum evaporation.
Solution Approach 2:
The patent applies different materials and structures to different regions of the OLED device. The pixel defining layer creates local variations in structure, with through-holes positioned at specific locations to allow electron transport and injection layers to be deposited only in required areas, optimizing material usage while preserving production efficiency.
2Loss of substance
If inkjet printing technology is used to manufacture OLED film layers, then material utilization rate is improved, but manufacturing precision decreases due to uneven film thickness
Solution Approach 1:
The pixel defining layer with strategically positioned through-holes segments the deposition area, guiding inkjet printing to deposit materials only in specific regions. This segmentation compensates for the PDL groove slope by creating defined zones where material deposition is controlled, improving both material utilization and film thickness uniformity.
Solution Approach 2:
The pixel defining layer acts as an intermediary structure that mediates between the inkjet printing process and the final film quality. The through-holes in the PDL serve as intermediaries that guide material flow and deposition, compensating for the uneven PDL groove surface and ensuring uniform film thickness while maintaining high material utilization.
3Shape
If the pixel defining layer groove has a slope, then device structure is formed, but inkjet printing precision decreases and film thickness becomes uneven
Solution Approach 1:
The patent introduces through-holes at specific locations within the PDL groove structure, creating local quality variations. These through-holes are positioned to compensate for the slope effect, ensuring that inkjet-printed materials are deposited uniformly in the light-emitting regions despite the overall sloped structure of the PDL groove.
Solution Approach 2:
The pixel defining layer with pre-formed through-holes is prepared before the inkjet printing process. This preliminary action creates a template that guides subsequent material deposition, pre-compensating for the PDL groove slope and ensuring uniform film thickness without requiring high precision during the actual printing process.
Data Source
AI summary
The present invention provides an organic light-emitting diode (OLED) device and a manufacturing of the OLED device. The OLED device includes a light-emitting layer, an insulating layer, an electron transport layer, and an electron injection layer. The insulating layer is arranged on one side of the light-emitting layer, and a through hole is in the insulating layer. The through hole is arranged corresponding to a middle portion of the light-emitting layer. The electron transport layer is in a lower portion of the through hole and attached to a surface of the light-emitting layer. The electron injection layer is in an upper portion of the through hole and attached to one side of the electron transport layer away from the light-emitting layer.